Flooring Member

ABSTRACT

A flooring member  10  comprises a metallic base layer  12,  a metallic intermediary layer  14,  a wooden upper layer  16  and a core  18  disposed between the base later  12  and the intermediary layer  14.  The core  18  is made from spaced plywood members  34  extending longitudinally through the flooring member between the base layer  12  and the intermediary layer  14.  Connection means  20, 22  are disposed on the edges of the flooring member  10  enabling a plurality of flooring members to assembled to make a floor.

The present invention relates to a flooring member and particularly, but not exclusively, to a flooring member for use with underfloor heating.

BACKGROUND OF THE INVENTION

A problem of solid wood flooring and engineered wooden flooring comprising a plywood base structure with a hardwood surface veneer is that it is an insulator and does not efficiently transmit heat from an underfloor heating system to a room space above the flooring. Typically an underfloor heating system installed underneath a wooden floor has to operate at a temperature between 2 and 5 degrees above the desired operating temperature to account for the undesirable insulating properties of the wooden floor.

It is an object of the invention to provide a flooring member having a wooden upper surface, which conducts heat more efficiently than flooring of the type described above.

SUMMARY OF THE INVENTION

According to the present invention there is provided a flooring member comprising a metallic base layer, a metallic intermediary layer, a wooden upper layer, and a core made from spaced plywood members mounted between the metallic base layer and the metallic intermediary layer.

The metallic layers provide enhanced heat transfer properties and also provide an even heat across the surface of the wooden upper layer.

Preferably the spaces between adjacent members of the plywood core extend between the metallic base layer and the metallic intermediary layer. The spaces may be filled with metallic material or alternatively may include a web extending between the layers to improve heat transfer between the layers.

The plywood members preferably extend longitudinally of the flooring member and the spaces are preferably longitudinally disposed between adjacent plywood members.

Corresponding first and second connection means may be disposed on respective longitudinal edges of the flooring member for connecting a plurality of flooring members together. The first connection means may comprise a half-dovetail slot extending along one edge of the flooring member and the second connection means may comprise a half-dovetail projection extending along the other edge of the flooring member.

The connection means are advantageous because they tend to draw adjacent members together, in use. Furthermore the first and second connection means may be made from metallic material, which improves conductivity of heat between the layers.

Preferably the wooden upper layer is made from a hardwood of between 2 mm and 6 mm thickness and is bonded to the metallic intermediary layer.

The metallic base layer and metallic intermediary layer are preferably made from aluminium, but may be made from any suitable metal or metal alloy with good thermal conductivity. The first and second connection means are preferably made from similar material.

In a preferred arrangement, the metallic base layer, metallic intermediary layer and connection means are formed from a single sheet of aluminium.

The flooring member typically has a thickness of between 15 and 22 mm.

BRIEF DESCRIPTION OF THE DRAWING

For a better understanding of the present invention, and to show more clearly how it may be carried into effect, reference will now be made, by way of example, to the accompanying drawings, in which:

FIG. 1 shows a schematic cross-sectional view through a flooring member of the invention.

DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENT

Referring to FIG. 1, a flooring member is indicated generally at 10. The flooring member 10 is a composite member and includes a metallic base layer 12, a metallic intermediary layer 14, a wooden upper layer 16 and a core 18 disposed between the base layer 12 and the intermediary layer 14. The upper layer 16 is typically made from a hardwood such as oak, ash or maple, but may, if desired, be made from softwood. The upper layer 16 is between 2 mm and 6 mm thick and is bonded to the upper surface of the intermediary layer 14 with adhesive. Ideally the upper layer 16 is as thin as possible, in order to reduce the insulative effect of the wood as much as possible. However, the wood must be thick enough to maintain its structural integrity and to provide a hard wearing surface. The upper layer 16 also needs to be thick enough to allow for sanding of the surface, once the flooring member 10 has been fitted in a floor.

First and second connection means 20, 22 extend longitudinally along the respective sides of the flooring member 10, to the left and right hand side of the flooring member respectively, as viewed. The connection means 20, 22 are made from the same material as the metallic base layer 12 and the intermediary layer 14. This substantially box shaped structure can be extruded or formed, for example, from aluminium, which has excellent heat conducting properties. Alternatively it can be formed from other metals or composite metals, such as galvanised steel. The first connection means 20 is a half-dovetail slot. The slot 20 has a lower surface 24 extending in a plane substantially perpendicular to the edge of the flooring member and parallel with the base layer 12, an upper surface 26 extending at an angle of approximately 15° relative to the base layer 12 upwards into the flooring member and a base surface 28 at the end of the slot extending substantially perpendicular to the base layer 12.

The second connection means 22 is a half dovetail projection with a cross section adapted to be received and engaged by a half dovetail slot 20 of another flooring member. The projection similarly comprises a lower surface 29 extending in a plane substantially perpendicular to the edge of the flooring member and parallel with the base layer 12, an upper surface 30 extending at an angle of approximately 15° relative to the base layer 12 upwards away from the edge of the flooring member and an end surface 32 extending substantially perpendicular to the base layer 12. Optionally the length of the projection 22 may be marginally less than the depth of the slot 20 to ensure that the projection does not touch the base of the slot 28, in use.

The core 18 is made from a plurality of spaced plywood members 34 extending longitudinally through the flooring member between the base layer 12 and the intermediary layer 14. In the embodiment shown, there are five parallel sided plywood members 34, adjacent members 34 being separated by space 36 of approximately 2 mm. In other arrangements, the plywood members 34 are narrower and the spaces 36 are larger. The plywood members 34 give strength to the flooring member, particularly when in compression and the purpose of the spaces is to allow for radiant heat to pass unimpeded between the plywood to the intermediary layer 14. Optionally the spaces 36 can accommodate or be filled with a heat conducting material such as a metallic foil or web. Optionally, spacers may be provided to maintain the spaces between the plywood members.

In use, a plurality of flooring members 10 can be connected together to construct a floor or other timber faced surface. The half dovetail projections 22 engage in the half dovetail slots 20 of adjacent members 10 and hold them together. The angled upper part of the joint tends to draw adjacent members 10 together and the members snap together with little effort. No adhesive is required. The members 10 can be fastened down in conventional manner using a nail gun, screw fixings or adhesive.

When a plurality of flooring members 10 are assembled into a floor, the transfer of heat from an under-floor heating system through the floor is much greater than that for a conventional wooden or structurally engineered timber floor. The adjoining base layers 12 and adjoining intermediary layers 14 have the effect of evening out the heat distribution across the floor and heat is conducted from the base layer 12 to the intermediary layer 14 through the interconnected connection means 20, 22. Furthermore, heat can radiate though the spaces 36 from the base layer to the intermediary layer. The addition of heat conducting material in the spaces 36 increases the rate of heat transfer.

The invention is beneficial because it enables under-floor heating systems to run at substantially lower temperatures than the prior art floors described for the same resultant surface temperature and heating effect. Furthermore, a system of flooring members 10 heats up more quickly than the prior art floors and the heat distribution is much more even, due to the effects of the base layer 12, the intermediary layer 14 and the increased number of efficient heat transfer positions between the layers 14, 16. The reduction in under-floor heating temperature is typically around 3° Celsius (C.), which is a significant reduction, given that typical operating temperatures are between 30 and 50° C.

Another advantage of the flooring members is that they are structurally strong due to their composite construction and are stable when subjected to under-floor heating. 

1. A flooring member comprising a metallic base layer, a metallic intermediary layer, a wooden upper layer, and a core made from spaced plywood members mounted between the metallic base layer and the metallic intermediary layer.
 2. A flooring member as claimed in claim 1, in which the spaces between adjacent members of the plywood core extend between the metallic base layer and the metallic intermediary layer.
 3. A flooring member as claimed in claim 2, in which the spaces are filled with metallic material.
 4. A flooring member as claimed in claim 1, in which the plywood members extend longitudinally of the flooring member and the spaces are longitudinally disposed between adjacent plywood members.
 5. A flooring member as claimed in claim 1, in which corresponding first and second connection means are disposed on respective longitudinal edges of the flooring member for connecting a plurality of flooring members together.
 6. A flooring member as claimed in claim 5, in which the first connection means comprises a half-dovetail slot extending along one edge of the flooring member and the second connection means comprises a half-dovetail projection extending along the other edge of the flooring member.
 7. A flooring member as claimed in claim 5, in which the first and second connection means are made from metallic material.
 8. A flooring member as claimed in claim 1, in which the wooden upper layer is made from a hardwood.
 9. A flooring member as claimed in claim 8 in which the hardwood upper layer is between 2 mm and 6 mm thickness and is bonded to the metallic intermediary layer.
 10. A flooring member as claimed in claim 1, in which the metallic base layer and metallic intermediary layer are made from aluminium.
 11. A flooring member as claimed in claim 5, in which the first and second connection means are made from aluminium.
 12. A flooring member as claimed in claim 1, in which the flooring member has a thickness of between 15 and 22 mm.
 13. A flooring member as claimed in claim 5, in which the metallic base layer, metallic intermediary layer and connection means are formed from a single sheet of aluminium. 